The following details installation and optimization of the Frauscher RSR110, dual segment wheel detector (aka. wheel sensor), utilizing the Rail Web Bolt kit.

Site Considerations:

The RSR110 wheel sensor must be mounted on the inside face of rail (wheel flange side), between ties (crib). Wheel sensor mounting utilizes the appropriate Rail Web Bolt Kit.
Different bolt kits are applicable to different gauge of rail. If upgrading from Tiefenbach wheel sensor, the Frauscher installation utilizes the same mounting holes. Skip section 2.1 on drilling the rail.
If mounting on a curve, the wheel sensor should be mounted on the rail which shows less lateral wear of head of rail. This is usually the inside rail.
Ensure when mounted that the housing edge of the wheel sensor does not touch the head of rail. (see Section 2.3)
2’ (600mm) minimum distance from rail joints (including welded joints).
10” (250mm) minimum distance from guard rails or other route’s rail/frog, etc., if mounted in a switch.
2’ (600mm) minimum distance from another Frauscher on the same rail.
3’ (1 meter) minimum distance from other manufacturer’s wheel detectors.
20” (500mm) minimum from ANY movable metal object

Requirements:

The APU-102 must have a TDA204, Track Directional Analyzer card, strapped for Frauscher Wheel detector.
Minimum AEI software version 5.2.0.6+

Parts Required:

400220, Frauscher Dual Segment Wheel Detector
400244, Frauscher Rail Web Bolt Kit, EXC10
400245, Frauscher Rail Web Bolt Kit, EXC10/21
400227, 5 Meter cable Assembly
400222, 10 Meter cable Assembly
400228, 25 Meter cable Assembly

Tools Required:

17mm 6-point socket
19mm 6-point socket
Ratchet handle (drive to fit sockets above)
Torque wrench (drive to fit sockets above), minimum torque range from 15 to 40 Nm (about 10-30 ft/lb)
6 mm hex key (Allen wrench)
Combination square or string and tape measure (metric preferred)
Shovel
Pick
Rake
Hammer
Misc. small hand tools.
Laptop PC with terminal emulation program (or someone with remote access to the APU)
Null modem Cable to Local Port (or connect via network if available)
Digital Voltmeter
Angle Grinder

Optional Tools Required:

400232, Drill guide
401178, Punch for guide
Rail mounted drill
17/32” bit (13mm), 400672 for Cembre, 400237 others.

Mounting the Frauscher Wheel Sensor

Drill the rail

1. Determine mounting location as outlined above. The crib chosen should be in line with the RFID antennas.

2. Clear the ballast from the crib, 4-6 inches below the foot of the rail.

3. Remove creeper clip(s) if necessary.

4. Trench for cable from the crib back to the track-side junction box or wiring pedestal. Usually “scratched” in, but follow your railroad’s standard practices.

5. Examine the rail web where the sensor will be mounted. If there is any raised lettering on the rail, grind flush to the rail web surface. (both sides of rail)

6. Refer to drawing 101-0008-00 as needed for steps that follow.

7. Secure and level the rail mounting template and tighten setscrew.

8. Insert the center punch into each hole and mark the rail by striking the center punch.

9. Remove template and drill two pilot holes (approximately 1/8” diameter and 1/8” deep) where marked to serve as a guide.

10. Using a rail mounted drill, drill two 17/32” (13mm) mounting holes, using the pilot holes as alignment guide.

11. Clear shavings and drill lubricant/coolant.

Mounting the Sensor to the Rail

If replacing a Tiefenbach, disconnect power from the TDA105 and remove the Tiefenbach from the rail. Examine the rail web where the sensor bolts will seat. If there is any raised lettering on the rail where the mounting bolts and nuts will seat, grind flush to the rail web surface. (both sides of rail)

Bolt kit EXC10 should work for most North American rail gauges. If measurement “B” is excessive after mounting, it will be necessary to change to bolt kit EXC10/21. Refer to Figure 3 below for “A” and “B” measurements.

1. Align the eccentric bolt kits as shown in Figure 1 for the 0° position and mount the bolt kits to the sensor (top of sensor facing up). Ensure the spring washer is installed correctly as shown in Figure 2. The 0° position is for proper vertical alignment (measurement “A”) on freshly drilled rail. Bolts can be rotated if necessary for rail wear. Refer to chart 1.

2. Leave loose enough for minor adjustment when attaching to the rail.

Figure 1

	Ensure that the conical spring washers are in the correct position (top surfaces must face outwards towards the locknuts).
Figure 2

3. Mount the sensor to the rail and secure with spring washer and locknut. Ensure the spring washer is installed correctly as shown in Figure 2. Snug up all mounting locknuts and check vertical and horizontal measurements are correct. If adjustments are required, refer to the appropriate section(s) below.

NOTE

When mounted, the sensor must not touch the rail head.

	Measurement “A” is from the top if the rail to the highest point of the top of the sensor. Measurement “A” can be checked with a combination square. Alternate method; span the gauge with a weighted string and measure from string to highest point of sensor. It must be between 40‐45mm (1 9/16 to 1 25/32 inches) Measurement “B” is from the inner surface of the wheel sensor to the outside of the railhead. It must be between 0‐6mm (0 to 1/4 inch)

Measurement "A" and "B"
Figure 3

Sensor Adjustment

Tighten rail mounting and sensor mounting nuts snugly. Verify both “A” and “B” measurements are correct. See Figure 3. If within specification, torque rail mounting nuts to 29.5 ft/lbs (40Nm) and the sensor mounting nuts to 11 ft/lbs (15Nm).
If vertical adjustment is necessary, note the current “A” measurement. Remove the sensor from the rail. For height (“A” measurement), the eccentric bolts can be rotated per Chart 1. Refer to Figure 1 for rotation.

'V'ERTICAL ALIGNMENT
"A" Measurement (mm)	"A" Measurement (in)	Eccentric Rotation
30 to 32.5	1 3/16 to 1 9/32	180°
32.5 to 37.5	1 9/32 to 1 15/32	120°
37.5 to 40	1 15/32 to 1 9/16	60°
40 to 45	1 9/16 to 1 25/32	No change required
More than 45 at highest mounting position	> 1 25/32	Redrill rail
Less than 30 at lowest mounting position	< 1 3/16	Redrill rail

Chart 1

If “B” measurement is excessive after mounting, it will be necessary to change to bolt kit EXC10/21. If the sensor is too far under the railhead, insert a 2mm washer between the eccentric bolt and the rail. (use spring washers from other bolt kit)

Remount and recheck measurements. If within specification, torque rail mounting nuts to 29.5 ft/lbs (40Nm) and the sensor nuts to 11 ft/lbs (15Nm).

Connect the Cable

Remove the connector flange from the sensor (6mm internal hex screws). Remove the protection caps from the clamp and cable. Insert the cable connector into the sensor. Reinstall the connector flange and torque the screws to 11 ft/lbs. (15Nm). Retain the protection caps at the site for future use. Feed the cable with cable/conduit assembly under the sensor and rail and
run back to the junction box/pedestal. If upgrading from a Tiefenbach with TDA105, remove the 2-pin power connector to the TDA105. Connect the cable at the junction box per the site wiring diagram, 70-0180-02. If replacing a Tiefenbach, the Frauscher sensor lead cable uses the same
color code.

At the APU-102.

Disable Maintenance Reporting

During the upgrade process, maintenance messages will be generated and may interfere with setting of some parameters. If your site has maintenance reporting, force a maintenance report with the SM command for each applicable session. After all have successfully reported, disable maintenance reporting for all applicable sessions.

Wiring to the APU-102

Connections will be from the surge protection devices directly to the APU-102. If upgrading from a Tiefenbach, the TDA105 will be removed from the system. Power off the APU-102 and rewire as necessary. Refer to drawing 70-0180-02 for details.

Strap the TDA204

Remove the TDA204 from the APU-102 if installed. If upgrading to TDA204, remove the TDA104 from the APU-102. Set or verify jumpers on the TDA204 are set for “DIRECT” and “FRAUSCHER”. Refer to drawing 70-0180-02 for details or legend on solder side of the TDA204. Set jumpers for BOTH segments. Install the TDA204 into the APU-102. (Cable connections inside the APU-102 are the same as TDA104). Power on the APU-102.

Configure the Parameters for the Frauscher Wheel Detector

Set/verify parameters for the Frauscher as follows (EP). Remaining parameters in this section will be set to default values. They should only be changed on advice from Comet Electronics Engineering staff.

Acquisition.Operating.WheelDetectorSeparation=50
Acquisition.Operating.WheelDetectorGain=50
Acquisition.Operating.WheelDetectorThreshold=50
Acquisition.Operating.WheelDetCsegMode=2
Acquisition.ACQProcess.Enabled=1
Acquisition.ACQProcess.MaxACQs=200
Acquisition.TDA204.Digitizer.DigitizerEnable=1
Acquisition.TDA204.Digitizer.DigitizerMaxFileSizeBytes=5000000
OR (depending on software version)
Acquisition.TDA204.Digitizer.DigitizerMaxFileSizeKBytes=10000

NOTE

Parameters may be changed, added or removed as the software evolves. Refer to the on-line parameter help, <CTRL>-U, as necessary.

Exit the parameter editor. Re-enter the parameter editor and verify the Acquisition.Operating parameters were set. Activities such as maintenance reporting, login and log off activity share the same file as these parameters. If not set correctly, set again, exit and re-verify. Perform a fast reboot (R,F) so changes take effect.

Calibrating the Frauscher Wheel Sensor

Log into the APU-102 to the Supervisory level on Session One (Change1> prompt). Ensure site is clear (no train). Later versions will allow you to terminate recording. Enter command TDA204 to enter the TDA204 setup utility.

NOTE

While running the TDA204 utility, the APU-102 will NOT record axles/trains. Commands within the TDA204 utility are hotkeys (do not follow command with <ENTER>). When done executing commands, the display will refresh.